Timing Belt and Drive, Water Pump and Oil Pump, Reassembly

Special Tools:
- Counterhold tool No. 999 5199, or equivalent
- Counterhold tool No. 999 5433, or equivalent
- Drift tool No. 999 5450, or equivalent
- Drift tool No. 999 5455, or equivalent
- Drift tool No. 999 5509, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Reconditioning". Tools and Equipment

Procedure





1. Install oil pump:
- Use new gasket.
- Use drift tool No. 999 5455, or equivalent when installing pump, using bolts as guides.
- Move pump in using crankshaft center nut.

NOTE: Do not allow crankshaft to rotate, as this may damage valves.

- Use thread locking compound part No. 1 161 056-5, or equivalent on bolts.
Tighten bolts alternately to 10 Nm.





2. Install belt drive pulley on crankshaft:
- Install belt drive pulley using the center nut and spacer.
- Install oil thermostat casing, using new O-ring.

NOTE: Do not let crankshaft rotate, as this may damage valves.





3. Install:
- Inner timing belt cover.
- Coolant pump, using new gasket.
Tighten bolts alternately to 20 Nm (15 ft lb).
- Thermostat and thermostat casing, using new gasket.





4. Fit upper timing belt cover:
- Install camshaft pulleys.
Align timing marks as shown.
- Insert two bolts in each pullet, tightening until just in contact with pulley.
- Lift upper timing belt cover off.

NOTE: Check that camshaft bolt holes are centered as illustrated.





5. Reinstall:
- Idler pulley, tighten to: 24 Nm (17.3 ft lb)
- Tensioner pulley, apply grease to surfaces of the actuator arm bushing, screw and sleeve.
Use lubricant part No. 1 161 246-2, or equivalent.
Tighten to: 30 Nm (22 ft lb)
- Tensioner/damper unit, tighten to: 24 Nm (17.3 ft lb)





6. Install timing belt:
- Place belt over camshaft pulleys, around water pump and press over tensioner pulley.
- Slacken two camshaft pulley bolts.
Remove locking pin from belt tensioner.
- Lock belt by tapping lightly (twice) with a plastic mallet between the camshaft pulleys and between the water pump and camshaft pulleys.
- Install plastic throw control washer.
- Install third bolt in each pulley and tighten all bolts to: 20 Nm (15 ft lb).
- Install upper transmission cover and belt guard.





7. Remove locking tools:
- Remove crankshaft locking tool No. 999 5451, or equivalent and install plug with new copper seal.
- Remove camshaft locking tool No. 999 5452, or equivalent.





8. Install camshaft rear seals:
- Use drift tool No. 999 5450, or equivalent.
- Grease seals.
- Press seals home until drift stops.

NOTE: If shaft ends show sign of wear, seal can be pressed in another 2 mm by turning tool sleeve.





9. Install vibration damper:
- Install vibration damper using counterhold tool No. 999 5433, or equivalent.
- Tighten center nut to 180 Nm (132 ft lb).
- Remove counterhold.
Tighten bolts to 25 Nm plus 30° (18 ft lb).





10. Check markings:
- Rotate engine crankshaft through two complete turns.
- Check that markings on crankshaft and camshaft pulleys line up.
- Install outer transmission cover.